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What is SEMI-FLEX?

SEMI-FLEX is a flex-rigid PCB, typically 4 layers, made entirely of FR4. Unlike conventional flex-rigid PCBs, the flexing element is not polyimide but a thin FR4 core with two layers of copper specially treated to flex without cracking. A less robust solution uses a depth-milled layer rather than a core.

Why use SEMI-FLEX?

SEMI-FLEX is flex-to-install. Unlike polyimide, the FR4 core is not capable of continuous flexing. However it will bend a limited number of times (typically 5 – see the technical specification below) at a controlled radius and to any angle. This makes it an ideal solution where you need to mount two PCBs in a unit at an angle to each other. Instead of using connectors and cables or a composite flex-rigid PCB, you can design a single FR4 SEMI-FLEX PCB which can be safely bent a sufficient number of times to allow installation and subsequent maintenance as needed.

The benefits of using SEMI-FLEX are:

Cost:

No need for connectors or cables

Less time needed for assembly

SEMI-FLEX is entirely FR4, so no need for boards made with expensive polyimide

Time:

Faster design time

Faster procurement

Faster build

Product reliability:

Fewer solder-joints

Eurocircuits SEMI-FLEX pool

Eurocircuits’ 4-layer SEMI-FLEX PCBs use a 100 micron central core for the flex area, with 35 micron high-ductility copper foil on each side. The stack is then made up on each side with a 510 micron FR4 core and two layers of no-flow pre-preg (see the full technical specification below). An alternative technology is to build a 2- or 4-layer PCB and then depth-mill the material away to leave a thin section as the flex area. We have adopted the core solution even though it needs more operations and so is a little more expensive. It gives a symmetrical build and so a more stable board, while depth-milling is difficult to control meaning that the flex area may have an irregular thickness. With a core-build we through-mill (rout) the pre-preg before pressing. We can then rout the outer layers with any minor variation in cutter depth being absorbed by the void.

The core build makes it easier to design a main board with up and down sections or a final Z-configuration.

SEMI-FLEX boards are preferably supplied in a panel to avoid any damage during transport or assembly.